GE Global Research, in partnership with GE–Fuel Cells, LLC and West Virginia University (WVU) will develop a thermal-spray, redox stable, ceramic anode that will enable robust, large scale, metal supported solid oxide fuel cells (SOFCs). The overall program objective is to define an optimized ceramic anode chemistry, and its thermal spray processing conditions, to enable scalable, low-cost, manufacturing utilizing GE’s extensive thermal spray network. Researchers will assess a single, simple redox stable anode composition: lanthanum doped strontium titanate combined with doped cerium oxide. Thermal spray manufacturing of a ceramic anode on a metal supported substrate will be demonstrated and material property requirements established. Sub-micron/micron sized powders with optimized composition and material properties will be produced for use in thermal spray manufacturing. GE Global Research will tailor the thermal spray process and engineer the powder microstructure to produce high performing SOFC cells. WVU will develop and down-select high performing ceramic anode chemistries that are amenable to the thermal spray process. Finally, GE–Fuel Cells will assemble, instrument, and operate a 5 kilowatt stack at its test lab for at least 1000 hours on natural gas or simulated natural gas fuel.

Project Benefits

The GE thermal sprayed redox stable anode has the potential to improve the reliability, robustness, and endurance of SOFC cell and stack technology while significantly reducing the cost. Removing the nickel may improve product lifetime by reducing or eliminating modes of degradation inherent in nickel based anodes, such as Ni-ripening and impurity poisoning. These more robust stacks will provide an operating cost benefit to the customer, while improving reliability and reducing maintenance costs and down time. Finally, by eliminating the nickel based materials in the anode, the processing of thermal spray powders is opened to a larger global market, thus reducing total manufacturing costs.